All-weather enclosure for flat panel displays

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application claiming U.S. Utility application Ser. No. 13/551,564 filed on Jul. 17, 2012 which derives benefit from U.S. Provisional App. No. 61/591,392 (“Improved All-Weather Enclosure for Flat Panel Displays”) filed on Jan. 27, 2012.

FIELD OF THE INVENTION

The present invention relates to an improved all-weather enclosure for flat panel displays including flat panel televisions.

BACKGROUND OF THE INVENTION

Flat panel displays, including flat panel televisions, computer displays, and displays used for digital signage have become far less expensive in recent years leading to the deployment of such devices in a multitude of unconventional physical locations, including exterior locations where they are exposed to the elements. For example, it is not unusual for flat panel televisions to be deployed in residential applications in the backyard near the family grill or overlooking the pool.

Unsurprisingly, products have been constructed to enclose these devices and shield them from the elements. Unfortunately, most have the same shortcomings, to wit: 1) They are made primarily of metal, metal and plastic, or even wood; and, 2) They are heavy, thus requiring that that they be mounted directly to a wall or other structure capable of bearing their weight and thus prohibiting their use with the standard ceiling and wall mounting systems commonly used to mount flat-panel displays today; and, 3) Because of the weight and complexity they are expensive.

To address these shortcomings, products constructed of lightweight plastic material have been developed. While such enclosures may be suitable for small flat-panel displays, when “scaled” to enclose the larger flat-panel displays now commonly available, such simple enclosures do not possess sufficient structural rigidity to adequately protect the flat-panel display. The principal difficulty arises because the use of readily available prefabricated light plastic material results in a relatively flimsy enclosure that deforms and warps easily, thus compromising the weatherproof nature of the enclosure. Moreover, because one large side of the enclosure must be constructed of some transparent material, such as polycarbonate, any warping of the enclosure also affects the optical clarity of the polycarbonate, thus distorting the image generated by the enclosed display. By using thicker, heavier plastic, such devices can be made with increased structural rigidity, but consequently such devices are heavier and more expensive to manufacture and mount.

Numerous alternative approaches have been disclosed. For example, products have been constructed that seek to increase the structural rigidity of the case by completely encasing the flat-panel display in a semi-permanently sealed box made of interlocking polycarbonate or plastic panels or the like. Such a device is disclosed by U.S. App. 2012/0120625. While certainly rigid, these devices are by no means lightweight. Other inventions disclose other types of semi-permanently sealed devices. Specifically, U.S. App. 2012/0039042 and U.S. App. 2012/0092818 both disclose devices in which the viewing element is adhesively sealed to the containing element and the flat-panel display is sealed within. While the inventions disclosed by U.S. Pat. No. 8,081,267 and U.S. Pat. No. 8,102,483 do not permanently seal the device within, they offer no easy means of ingress for maintenance or adjustment of the enclosed flat-panel display. These sealed devices are thus unsuitable for ordinary consumer and home use. To provide an improved means for ingress and access, U.S. App. 2009/0231807 discloses a device that has a flip-up front panel for accessing the flat-panel display within. Unfortunately, this device is constructed of a multitude of parts and is quite heavy thus making it impractical if not mounted directly to a wall. Today, flat-panel displays are mounted in a wide variety of locations, both directly attached to walls and “free-standing” hanging from ceiling mounts and wall mounts. Finally, all of the above inventions contain numerous constituent parts and are costly to manufacture.

Accordingly, one goal of the present invention is to provide a device to enclose and protect a flat-panel display that is both simple to manufacture, inexpensive, and lightweight and yet rigidly constructed such that it does not easily warp or deform. A second goal of the present invention is to provide a hinged transparent viewing panel thus providing a convenient means of accessing the interior of the enclosure to mount, adjust, and maintain the flat panel display mounted within. A third goal of the present invention is to ensure that the requisite transparent viewing pane remains planar and that the requisite elastomeric seal between the transparent viewing panel and the body of the device is continuously and evenly compressed between the viewing pane and the body of the device thus ensuring that the enclosed flat-panel display is completely protected from the elements.

BRIEF SUMMARY OF THE INVENTION

According to the preferred embodiment of the invention, a plastic housing for flat panel displays comprised of a front, planar viewing element and a rear, recessed containing element is disclosed.

The front, planar viewing element is constructed of substantially transparent polycarbonate or other suitable material and may include one or more non-reflective, anti-glare surfaces. Applied continuously to the inner aspect of the viewing element and along its outer edge is a sealing strip comprised of rubber or other elastomeric material. At the bottom edge of the viewing element are one or more regularly spaced knobs or similar, lifting means. Similarly, extending through the bottom edge of the viewing element are one or more compression key latches, or similar locking means.

The containing element is constructed of polystyrene, high-density polyethylene, or some similar substance and is generally in the form of a recessed shallow rectangular prism reinforced with a network of molded indentations formed in its outer surface. These molded indentations serve to increase the structural rigidity of the containing element. While these indentations are regularly spaced across the outer surface of the containing element, they are absent in the center portion of the back wall of the containing element to allow for drilled or molded holes used to secure the flat panel display and protective enclosure to a standard mounting device. Also, the lower wall of the containing element has one or more mating slots, molded indentations, or similar tang receiving means that interoperate with the locking tangs present on the compression key latches, or similar locking means, attached to the viewing element. The bottom wall of the containing element is perforated to allow access for power and signal cables. Similarly, the left and right sides of the containing element are perforated by one or more air vents.

The viewing element and containing element are attached at their respective tops by a continuous piano hinge, or equivalent hinging means. The viewing element swings down to close thus compressing the sealing strip attached to the containing element between the viewing element and the containing element. Inserted at regular intervals through the peripheral back of the containing element along its bottom and left and right sides are a multiplicity of threaded screws or studs that in turn protrude through concentric holes drilled or otherwise formed in the overlying sealing strip and the viewing element (when the latter is closed over the containing element). The viewing element is secured to the containing element by: 1) Screwing a threaded screw cap onto an each of the protruding threaded screws or studs extending above the plane of the viewing element; and, 2) Actuating the compression key latches, or similar locking means, such that their tangs interoperate with the mating slots, molded indentations, or similar tang receiving means, present in the bottom wall of the containing element. The process of screwing the threaded screw caps onto the protruding threaded screws of studs squeezes the sealing strip between the containing element and the viewing element thus serving to tension the reinforced containing element together with the viewing element to form a rigid, monocoque structure. Hinged prop rods, or a similar propping means, for holding the viewing element in the open, up position relative to the containing element, are provided on the inner aspect of the left and right sides of the viewing element adjacent to the left and right edges of the viewing element. To hold the viewing element in the up, open position the distal end of each prop rod is inserted in a mating hole in the upper edge of the adjacent side wall of the containing element. When closed, these prop rods are positioned unobtrusively inside the sealed unit so that they do not interfere with the flat panel display.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects, advantages, and novel features of the present invention will be more readily appreciated from the following detailed description of a preferred embodiment thereof when read in conjunction with the accompanying drawings, in which:

<figref idref="DRAWINGS">FIG. 1</figref> illustrates an oblique, front view of the present invention with the viewing element partially open.

<figref idref="DRAWINGS">FIG. 2</figref> illustrates a, oblique top and front view of the present invention with the viewing element closed and locked.

<figref idref="DRAWINGS">FIG. 3A</figref> illustrates a detail view of a compression latch as used in the preferred embodiment of the present invention.

<figref idref="DRAWINGS">FIG. 3B</figref> illustrates a detail view of the double stepped flange extending outward from the containing element of the device, a partial cutaway view of the sealing strip and the one sealing screw and sealing cap used to secure the viewing element to the containing element.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, a protective enclosure <b>100</b> used to enclose and protect a flat panel display, or equivalent, comprised of a front, planar viewing element <b>120</b> and a rear, recessed containing element <b>130</b> is disclosed.

The front, planar viewing element <b>120</b> is constructed of substantially transparent polycarbonate or other suitable transparent material and may include one or more non-reflective, anti-glare surfaces. The rear, recessed containing element <b>130</b> is in the general form of a shallow rectangular prism open on one large side. Containing element <b>130</b> is constructed from polystyrene, high-density polyethylene, or some similar substance. Containing element <b>130</b> may be manufactured using many different techniques, but conventional vacuum-forming technology is preferred. To ensure maximal structural rigidity of the device, a regular network of reinforcing depressions (as exemplified by <b>131</b>) is formed in the back surface of containing element <b>130</b> except at the horizontal and vertical center point of the back surface of containing element <b>130</b> where a discontiguous planar mounting surface is retained. Evenly arranged within this mounting surface are a series of mounting holes <b>132</b> used to affix the enclosed flat panel display, or equivalent, to the wall or hanging mount supporting them. Those skilled in the art will recognize that the mounting holes provided on modern flat panel displays and mounts are arranged in standard patterns, with specific arrangements and dimensions being selected from a group referred to as the Flat Display Mounting Interface (FDMI) or more commonly the VESA mounting standard. Accordingly, one or more groups of mounting holes <b>132</b> are molded or otherwise formed in this planar mounting surface conforming to one or more patterns selected from this standard. Those skilled in the art will recognize that this standard may evolve over time and that future configurations are implicitly included in the spirit and scope of this disclosure.

Referring now to <figref idref="DRAWINGS">FIGS. 1 and 3B</figref>, extending outward at nearly a right angle from the top (open) edge of the four shallow walls thus formed in containing element <b>130</b> is a continuous, double stepped flange with lip. This flange has a lower, first surface <b>133</b> and a higher, second surface <b>134</b> situated above. Extending outward from higher, second surface <b>134</b> and bending down and over, is lip <b>135</b>. Combined together, lower, first surface <b>133</b>, higher, second surface <b>134</b>, the stepped construction utilized to construct them, and lip <b>135</b> extending downward from higher, second surface <b>134</b> provide enhanced structural rigidity to containing element <b>130</b>. Applied continuously to lower, first surface <b>133</b> of containing element <b>120</b> is sealing strip <b>121</b> comprised of rubber or some other elastomeric material. When protective enclosure <b>100</b> is closed and secured, sealing strip <b>121</b> is evenly compressed between lower, first surface <b>133</b> and viewing element <b>120</b>. This helps ensure a weather tight seal.

Referring again to <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, attached linearly to the top of higher, second surface <b>134</b> along the topmost of the two long edges of the recessed containing element <b>130</b> is hinging means <b>136</b>. Hinging means <b>136</b> is used to affix viewing element <b>120</b> to containing element <b>130</b> in such a way that viewing element <b>120</b> may be swung up and away from containing element <b>130</b> so that the enclosed flat panel display may be accessed and manipulated. Since hinging means <b>136</b> is attached to the full length of higher, second surface <b>134</b> of the topmost of the two long edges of recessed containing element <b>130</b>, hinging means <b>136</b> adds additional structural rigidity to containing element <b>130</b>. To further add structural rigidity to containing element <b>130</b>, attached linearly to the bottom of higher, second surface <b>134</b> along the full length of the topmost of the two long edges of the containing element <b>130</b>, is lightweight reinforcing bar <b>137</b> constructed of steel, aluminum, or other suitable rigid material. Reinforcing bar <b>137</b> may be in any of a number of conventional shapes, including, but not limited to, a flat bar, an L-shaped angle bar, or a U-shaped bar. Hinging means <b>136</b> is affixed to reinforcing bar <b>137</b> by means a multiplicity of rivets <b>144</b>, screws, or other attaching means passed through reinforcing bar <b>137</b>, then through higher, second surface <b>134</b>, then through hinging means <b>136</b>.

Hingedly attached along the inner aspect of the left and right sides of viewing element <b>120</b> adjacent to the left and right edges of viewing element <b>120</b> are prop rods <b>122</b> or similar propping means. To hold viewing element <b>120</b> in the up, open position, the distal end of each prop rod <b>122</b> is inserted in a mating hole <b>138</b> drilled or otherwise formed in the higher, second surface <b>134</b> of the adjacent side wall of the containing element <b>130</b>. When closed, prop rods <b>122</b> are positioned unobtrusively inside the sealed unit so that they do not interfere with the flat panel display.

At the center point of the lower, long shallow wall of recessed containing element <b>130</b>, an access hole <b>139</b> is formed and into this access hole a rubber grommet <b>140</b> or equivalent is inserted such that necessary power, video, and data cables can unobtrusively exit from the bottom of the device to provide necessary interconnections with an external power source and other devices. Similarly, at the top of each of the shorter, side shallow walls of containing element <b>130</b> a vent hole <b>141</b> is formed or installed in containing element <b>130</b> thus allowing warm air to escape from the upper aspects of the device when a flat panel display is installed. Vent hole <b>141</b> may be louvered and oriented such that rain cannot enter the closed protective enclosure.

Referring now to <figref idref="DRAWINGS">FIGS. 1, 3A, and 3B</figref> along the bottom edge of viewing element <b>120</b> are one or more regularly spaced compression key latches <b>124</b>, or similar locking means with locking tangs <b>125</b>. The locking tangs <b>125</b> of compression key latches <b>124</b> interoperate with mating slots <b>143</b>, molded indentations, or similar tang receiving means present in the bottom shallow wall of containing element <b>130</b>. When viewing element <b>120</b> is closed against containing element <b>130</b> the user actuates compression key latch(es) <b>124</b> such that their tang(s) <b>125</b> interoperate with the mating slots <b>143</b> or molded indentations present in the bottom shallow wall of the containing element <b>130</b>. By this means, the user may securely lock viewing element <b>120</b> to containing element <b>130</b> to prevent unauthorized tampering or theft of the enclosed flat panel display.

Referring now again to <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, at the bottom edge of viewing element <b>120</b> are one or more regularly spaced knobs <b>123</b> or similar lifting means. Knob(s) <b>123</b> provide(s) a convenient means of manually lifting viewing element <b>120</b> up and away from containing element <b>130</b> into its fully propped position.

Referring now to <figref idref="DRAWINGS">FIGS. 2 and 3B</figref>, when viewing element <b>120</b> is closed on containing element <b>130</b>, a series of regularly spaced holes drilled or otherwise formed through viewing element <b>120</b>, sealing strip <b>121</b>, and lower, first surface <b>133</b> concentrically align such that the threaded shaft of each sealing screw <b>145</b> affixed to the rear of lower, first surface <b>133</b> projects up and through lower, first surface <b>133</b>, sealing strip <b>121</b>, and viewing element <b>120</b>. To seal viewing element <b>120</b> to containing element <b>130</b> and evenly compress sealing strip <b>121</b> between the two, threaded caps <b>146</b> or other sealing means are screwed onto the threaded ends of sealing screws <b>145</b> as they project above the plane of viewing element <b>120</b>. By affixing threaded caps <b>146</b> to the projecting threaded ends of sealing screws <b>145</b>, viewing element <b>120</b> is firmly secured to containing element <b>130</b> compressing sealing strip <b>121</b> between thus forming a hollow, rigid monocoque structure. This adds to the overall structural rigidity of protective enclosure <b>100</b> when closed and serves to limit the mechanical distortion of the unit when mounted thus improving weather-tightness and optical performance.

Referring again to <figref idref="DRAWINGS">FIG. 1</figref>, protective enclosure <b>100</b> can comprise many different materials. As discussed earlier, containing element <b>130</b> is preferably constructed of polystyrene or high-density polypropylene. Nevertheless, other materials are equally suitable. Acrylonitrile butadiene styrene, polyethylene terephthalate, and polycarbonate are all also suitable. Also, lightweight aluminum panels may be pressed into, and fiberglass may be molded into, equivalent shapes. Similarly, while viewing element <b>120</b> is ideally constructed of polycarbonate, other materials are suitable. Polyethylene terephthalate and laminated glass are but two examples.

In an alternative embodiment of the present invention, a multiplicity of light-emitting diodes may be regularly installed along the peripheral edge of the viewing element <b>120</b> or through lower first surface <b>133</b> and sealing strip <b>121</b>, such that when illuminated the viewing element acts as a planar light guide and is illuminated with an even light of the same color as the light-emitting diodes. This is particularly useful when blue light-emitting diodes are installed due their ability to counter surface glare on a conventional polycarbonate sheet to glare in bright sunlight. Thus, the underlying flat panel display is rendered more easily visible in sunlit conditions. The electrical circuit illuminating the installed light emitting diodes may be controlled by a photodiode or other means of sensing ambient light levels and a modulating circuit so that the light-emitting diodes are on only when it is sunny and dynamically adjust in intensity as sun conditions change.

In an alternative embodiment of the present invention, a fan or other ventilating device is affixed to protective enclosure <b>100</b> to exhaust warm air from the interior of the device to the outside. This fan may be powered by any known means including but not limited to a direct electrical connection or by a battery and/or a solar cell.

In another alternative embodiment of the present invention, an active cooling and/or heating system may be affixed to protective enclosure <b>100</b> to maintain a relatively constant temperature or humidity inside the device. This active cooling and/or heating system may be of any known type including but not limited to, for example, Peltier devices and electric heating elements and may be powered by any known means including but not limited to a direct electrical connection or by a battery and/or a solar cell. Conventional external forced or refrigerated air cooling systems are well known in the art and are included herein by reference.

In an alternative embodiment of the present invention, one or more active or passive dehumidifying devices are included inside the device to dehumidify the interior of the device to help protect the flat panel display.

While the invention has been described in connection with what are considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the disclosure. More specifically: 1) Variants that alter the number or arrangement of depressions formed in the back panel of the containing element; and/or, 2) Variants that seek to change the overall shape of the device, from its present shallow rectangular prism form to another form; and/or, 3) Variants that seek to enclose a multiplicity of flat panel displays in a single enclosure; and/or, 4) Variants that seek to provide a lightweight external supporting framework or structure coupled with a recessed containing element constructed of reinforced or unreinforced lightweight plastic material; and/or, 5) Variants that provide an integral sun-shade, rain shade, or similar device either attached to, or integral with, the present invention to further protect the enclosed display are included within the spirit and scope of the disclosure.